Fillauer Formula User manual

Formula™
Product Manual

2
Instructions
The Fillauer Formula™ foot system has been designed and manufactured
for specic patient weights. Failure to follow the weight guidelines and/or
overload conditions caused by the patient, such as heavy lifting, high impact
sports, or abusive activities that would otherwise damage the natural limb,
may void the warranty.
• Please review the FAQ section of the manual on page 11 before use of
the foot. These instructions should be read prior to tting and followed
to ensure the proper integration of the Formula foot into the patient’s
prosthetic system.
• The foot selection is primarily based on the patient’s weight and foot
size. The patient’s height should be considered as well as the height
of attachment. A Fillauer Product specialist can help determine the
appropriate category for your patient. Contact Customer Service at
1-800-251-6398.
Product Specications
Weight rating: 330 lbs. (150 kg)
Foot size: 22 – 31 cm
Functional levels: K3 – K4
Weight (27cm foot): 24 oz. (675 g)
Pylon height: 12 – 20 in. (30 – 21cm)
Build height: 3in. (7.6cm)
3 in.
(7.6 cm)
1 in. (2.5 cm)
⅜ in. (10 mm)
12 – 20 in.
(30 – 51 cm)
5° Posterior
Pylon Lean

3
Installation
Attention: Deviating from the installation instructions or modifying the foot
in any way other than as recommended in this manual will void any product
warranty and could lead to product failure and injury to the patient.
Pylon & Foot Plate Setup
1. Lightly sand the plantar surface of both the heels and the plantar
surface of the pylon from the point of the heel attachment holes to the
toe to ensure a proper bond of the sole. Install the patch of 220 grit
sandpaper over the attachment area with a distal line of superglue.
2. Attach the heels with a minimum gap of ⅛ in., and separate toe springs
with a ⅛ in. spacer, such as a drill bit, to hold them apart temporarily. If
two sets of bolts are included, be sure to choose the bolt set that does
not extend through the T-nuts.

4
3. With the ⅛in. spacer in place, glue 3 pieces of ⅜in. cloud crepe to the
topside of heels. All crepe gluing in this process must be done with
heated material so it molds properly.
4. Remove the heel and sand to the shape of the outer edge of the heel
plates. Keep in mind that we will be adding ¼in. of additional crepe to
outside in step 5.
5. Glue Soleex (moderately dense) crepe around the outside of the heel
plate and sand the top and bottom to match the contour of heel plate
and the wedge created in step 4.

5
6. Reattach the heel section to the pylon using the bolts provided and
torque to 18 – 20N·m.
7. Measure the desired length of the foot. Always cut back the length from
the toe, never from the heel. Cut and sand the asymmetric shape of the
toe of the foot (right or left). With the drill bit still holding the toe apart,
glue ¼in. Soleex crepe to plantar surface of toe only.
8. Glue ½in. inch Soleex on the full length of foot, and another ½in. on
posterior two thirds. Remove the drill bit.

6
9. Sand the shape of the foot so it ts in the desired shoe. The shape must
have a medial arch carved to match the last of the shoe. It is important
that the lateral edge matches the shape of the shoe so the foot does
not shift or cause damage to the shoe over time. Use a band saw to
split the sole down the center by following the split in the foot plate.
The entire sole needs to be split so the two halves move independently.
10. The foot should have a slight arch from the heel to the metatarsal
heads, and then rocker slightly from metatarsal heads to the toe. Flatter
shoes will require less arch; dress shoes, boots, and shoes with higher
heel angles will require more arch. Plantar/dorsiexion of the foot is
done by sanding the desired angle to the plantar surface of the crepe
material.

7
Installation & Alignment
1. An alignment plate and instructions are available from Fillauer
(PN180-10-2010); however, for the best cosmetic nish direct
lamination of the foot to the socket can be easily accomplished.
2. The foot should rst be cut to length to allow attachment as proximal as
can be allowed by the posterior trimline of the socket. The proximal
edge should then be beveled to prevent excess bulk or hard edges.
3. Alignment of the foot can be done by following a tracing of the patient’s
current prosthesis or a dynamically aligned test socket. The socket
should be attached with an additional 3 – 5° of posterior lean to
accommodate compression of the longer foot (this will be a starting
point but will vary due to patient weight, posture, and the length of the
proximal pylon).

8
4. Bond the socket to the pylon using Fabtech PLUSeries® Composite
Adhesive as shown. Check the alignment and correct by rebonding the
setup before proceeding to the next step.
5. Once the static alignment is complete, apply an outer layer of adhesive
to hold the foot in place for dynamic alignment (for larger patients,
berglass cast tape may be necessary for safety).
Apply adhesive
in area shown
Apply adhesive
in area shown

9
6. To make any changes to alignment during the dynamic alignment stage,
grind away the outer layer of adhesive to release the foot and mark the
foot as shown above to make changes easy to visualize. Also, a simple
wedge can be used to hold alignment changes changes the socket
position while the foot is reattached.
7. Repeat steps 4 – 6 until optimal alignment is achieved.
8. As an alternative to the direct lamination attachment, the Fillauer
alignment plate may be used to attach the foot but an additional ⅜in.
posterior oset is required.
Add reference
marks to aid
alignment

10
9. Sand the exterior of the adhesive and the socket to just past the midline
to allow for a solid bond of the lamination. Mask the socket anterior to
trimline and distal and proximal to the adhesive. Apply carbon ber
braid, fully saturated with resin, to the sanded area and tightly wrap
with PVA to seal as the lamination sets.
Top Cover Fabrication
1. Use EVA foam to create the dorsal section of the foot cover
2. Heat the foam until pliable and glue to the upper surface of the pylon.
Grind the foam block to shape it to the appropriate size for the foot.
EVA Foam
Block
Apply contact
cement to
dorsal surface

11
3. Heat ¼in. thick crepe and glue over the EVA foam to create a durable
top cover.
4. The nal product may then be sanded and a nish lamination or clear
coat of paint may be applied to the socket for a gloss nish.
Frequently Asked Questions
What can the practitioner do if the heel or toe is too soft or
toorm?
The heel and toe rollover resistance may also be ne-tuned during the
dynamic alignment (page 8) by plantarexing, dorsiexing, shifting the
foot anterior or posterior, or sanding the desired angle to the plantar surface
of the crepe material.
Can the foot be worn without a shoe?
Yes, the foot may be used without a shoe; however, some type of protective
covering must be used on the plantar surface to protect the composite
blades from abrasion and high impact. A durable sole material must be
permanently bonded using Master® All-Purpose Cement or equivalent
adhesive to the plantar surface of the foot assembly to provide the necessary
traction and protection.
Can I get my Formula wet?
The Formula is designed to be maintenance free. The foot is water proof;
however, if the foot is submerged in salt water, the proximal foot bolts
should be rinsed with fresh water and dried immediately. Also, if the crepe
becomes soaked, it should be allowed to dry outside the shoe.

Fillauer LLC
2710 Amnicola Highway
Chattanooga, TN 37406
423.624.0946
Fax [phone]www.llauer.com
© 2017 Fillauer LLC
M072/06-19-17/10-05-17
Is there regular maintenance on the foot for which I should see
myprosthetist?
The Formula is a high performance foot and should be inspected every
6months for signs of abnormal wear and that the attachment/alignment
screws are secure. Any foreign materials or grit must be routinely cleaned
away to prevent excessive wear.
How should I clean my foot?
Patients should clean the prosthetic foot with a soft cloth and a soap and
water solution. The foot should be inspected for the presence of sand or
other debris on a weekly basis. Periodic cleaning is highly recommended to
prevent any excessive wear or noise issues.
What should I do if my foot is no longer performing as well or is
making noise when in use?
If the foot performance changes or if it makes noise, the patient should
immediately contact his or her practitioner.
Warranty
• 24 months from date of patient tting
The Formula foot system has been designed and manufactured for specic patient
weights. Failure to follow the weight guidelines and/or overload conditions caused by
the patient, such as heavy lifting, high impact sports, or abusive activities that would
otherwise damage the natural limb, may void the warranty.
Patient Trial
• A patient trial is not available for posterior mounted feet